REXRTOHRexroth EcoDrive 03 Drive Controllers DKC**.3-040, -100, -200

1 Important Notes

1.1 Safety Instructions

General Information

• Do not attempt to install or commission this device without first reading

all documentations provided with the product. Read and understand

these safety instructions and all user documentation prior to working

with the device. If you do not have the user documentation for the

device, contact your responsible Bosch Rexroth sales representative.

Ask for these documents to be sent immediately to the person or

persons responsible for the safe operation of the device.

• If these documentations contain some information you do not

understand, it is absolutely necessary that you ask Bosch Rexroth for

explanation before you start working on or with the devices.

• Only persons who are trained and qualified for the use and operation

of the device may work on this device or within its proximity. The

persons are qualified if they have sufficient knowledge of the

assembly, installation and operation of the equipment as well as an

understanding of all warnings and precautionary measures noted in

this documentation.

• Only trained, instructed and qualified persons are allowed to switch

electrical circuits and devices on and off in accordance with technical

safety regulations, to ground them and to mark them according to the

requirements of safe work practices. These persons must have

adequate safety equipment and be trained in first aid.

• Technical data, connections and operational conditions are specified in

the reference documentations for the product and must be followed at

all times.

• If the products take the form of hardware, then they must remain in

their original state, in other words, no structural changes are permitted.

It is not permitted to decompile software products or alter source

codes.

• Do not mount damaged or faulty products or use them in operation.

• Only use spare parts and accessories approved by Bosch Rexroth.

• Follow all safety regulations and requirements for the specific

application as practiced in the country of use.

• If the device is resold, rented and/or passed on to others in any other

form, these safety instructions must be delivered with the device in the

official language of the user's country.

• Proper and correct transport, storage, assembly and installation as

well as care in operation and maintenance are prerequisites for

optimal and safe operation of this device. Observe the data contained

in the corresponding product documentations.

WARNING

Improper use of these devices, failure to follow the safety instructions in this

document or tampering with the product, including disabling of safety devices, may

result in material damage, bodily harm, electric shock or even death!

⇒ Observe the following safety instructions!

Contact with Electrical Parts

DANGER

High electrical voltage! Danger to life, electric shock and severe bodily injury!

• Follow general construction and safety regulations when working on power installations.

• Before switching on the device, the equipment grounding conductor must have been

non-detachably connected to all electrical equipment and motors in accordance with the

connection diagram.

The equipment grounding conductor of the electrical equipment and the units must be

non-detachably and permanently connected to the power supply unit at all times. The

leakage current is greater than 3.5 mA.

Over the total length, use copper wire of a cross section of a minimum of 10 mm2

 for

this equipment grounding connection!

• Before working with electrical parts with voltage potentials higher than 50 V, the device

must be disconnected from the mains voltage or power supply unit. Provide a safeguard

to prevent reconnection.

• Wait 30 minutes after switching off power to allow capacitors to discharge before

beginning to work. Measure the electric voltage on the capacitors before beginning to

work to make sure that the equipment is safe to touch.

• Never touch the electrical connection points of a component while power is turned on.

• Install the covers and guards provided with the equipment properly before switching the

device on. Before switching the equipment on, cover and safeguard live parts safely to

prevent contact with those parts.

• A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives!

Indirect contact must be prevented by other means, for example, by an overcurrent

protective device according to the relevant standards.

Handling and Assembly

CAUTION

Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting!

• Observe the general construction and safety regulations on handling and assembly.

• Use suitable devices for assembly and transport.

• Avoid jamming and bruising by appropriate measures.

• Always use suitable tools. Use special tools if specified.

• Use lifting equipment and tools in the correct manner.

• If necessary, use suitable protective equipment (for example safety goggles, safety shoes,

safety gloves).

• Do not stand under hanging loads.

• Immediately clean up any spilled liquids because of the danger of skidding.

Dangerous Movements

Dangerous movements can be caused by faulty control of connected

motors. Some common examples are:

• improper or wrong wiring of cable connections

• incorrect operation of the equipment components

• wrong input of parameters before commissioning

• malfunction of sensors, encoders and monitoring devices

• If the device is resold, rented and/or passed on to others in any other

form, these safety instructions must be delivered with the device in the

official language of the user's country.

• Proper and correct transport, storage, assembly and installation as

well as care in operation and maintenance are prerequisites for

optimal and safe operation of this device. Observe the data contained

in the corresponding product documentations.

Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! ⇒ Observe the following safety instructions!

Contact with Electrical Parts

DANGER

High electrical voltage! Danger to life, electric shock and severe bodily injury!

• Follow general construction and safety regulations when working on power installations.

• Before switching on the device, the equipment grounding conductor must have been

non-detachably connected to all electrical equipment and motors in accordance with the

connection diagram.

The equipment grounding conductor of the electrical equipment and the units must be

non-detachably and permanently connected to the power supply unit at all times. The

leakage current is greater than 3.5 mA.

Over the total length, use copper wire of a cross section of a minimum of 10 mm2

 for

this equipment grounding connection!

• Before working with electrical parts with voltage potentials higher than 50 V, the device

must be disconnected from the mains voltage or power supply unit. Provide a safeguard

to prevent reconnection.

• Wait 30 minutes after switching off power to allow capacitors to discharge before

beginning to work. Measure the electric voltage on the capacitors before beginning to

work to make sure that the equipment is safe to touch.

• Never touch the electrical connection points of a component while power is turned on.

• Install the covers and guards provided with the equipment properly before switching the

device on. Before switching the equipment on, cover and safeguard live parts safely to

prevent contact with those parts.

• A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives!

Indirect contact must be prevented by other means, for example, by an overcurrent

protective device according to the relevant standards.

Handling and Assembly

CAUTION

Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting!

• Observe the general construction and safety regulations on handling and assembly.

• Use suitable devices for assembly and transport.

• Avoid jamming and bruising by appropriate measures.

• Always use suitable tools. Use special tools if specified.

• Use lifting equipment and tools in the correct manner.

• If necessary, use suitable protective equipment (for example safety goggles, safety shoes,

safety gloves).

• Do not stand under hanging loads.

• Immediately clean up any spilled liquids because of the danger of skidding.

Dangerous Movements

Dangerous movements can be caused by faulty control of connected

motors. Some common examples are:

• improper or wrong wiring of cable connections

• incorrect operation of the equipment components

• wrong input of parameters before commissioning

• malfunction of sensors, encoders and monitoring devices

• defective components

Courtesy 

• software or firmware errors

Dangerous movements can occur immediately after equipment is

switched on or even after an unspecified time of trouble-free operation.

The monitoring in the drive components will normally be sufficient to avoid

faulty operation in the connected drives. Regarding personal safety,

especially the danger of bodily harm and material damage, this alone

cannot be relied upon to ensure complete safety. Until the integrated

monitoring functions become effective, it must be assumed in any case

that faulty drive movements will occur. The extent of faulty drive

movements depends upon the type of control and the state of operation.

DANGER

Dangerous movements! Danger to life, risk of injury, severe bodily harm or material

damage!

• For the above reasons, ensure personal safety by means of qualified and tested higherlevel monitoring devices or measures integrated in the installation.

They have to be provided for by the user according to the specific conditions within the

installation and a hazard and fault analysis. The safety regulations applicable for the

installation have to be taken into consideration. Unintended machine motion or other

malfunction is possible if safety devices are disabled, bypassed or not activated.

To avoid accidents, bodily harm and/or material damage:

• Keep free and clear of the machine’s range of motion and moving parts. Possible

measures to prevent people from accidentally entering the machine’s range of motion:

– use safety fences

– use safety guards

– use protective coverings

– install light curtains or light barriers

• Fences and coverings must be strong enough to resist maximum possible momentum.

• Mount the emergency stop switch in the immediate reach of the operator. Verify that the

emergency stop works before startup. Don’t operate the device if the emergency stop is

not working.

• Isolate the drive power connection by means of an emergency stop circuit or use a safety

related starting lockout to prevent unintentional start.

• Make sure that the drives are brought to a safe standstill before accessing or entering the

danger zone.

• Additionally secure vertical axes against falling or dropping after switching off the motor

power by, for example:

– mechanically securing the vertical axes,

– adding an external braking/ arrester/ clamping mechanism or

– ensuring sufficient equilibration of the vertical axes.

• The standard equipment motor brake or an external brake controlled directly by the drive

controller are not sufficient to guarantee personal safety!

• Disconnect electrical power to the equipment using a master switch and secure the switch

against reconnection for:

– maintenance and repair work

– cleaning of equipment

– long periods of discontinued equipment use

• Prevent the operation of high-frequency, remote control and radio equipment near

electronics circuits and supply leads. If the use of such devices cannot be avoided, verify

the system and the installation for possible malfunctions in all possible positions of normal

use before initial startup. If necessary, perform a special electromagnetic compatibility

(EMC) test on the installation.

Magnetic and Electromagnetic Fields

WARNING

Health hazard for persons with heart pacemakers, metal implants and hearing aids in

proximity to electrical equipment!

• Persons with heart pacemakers and metal implants are not permitted to enter following

areas:

– Areas in which electrical equipment and parts are mounted, being operated or

commissioned.

– Areas in which parts of motors with permanent magnets are being stored, repaired or

mounted.

• If it is necessary for somebody with a pacemaker to enter such an area, a doctor must

be consulted prior to doing so. The interference immunity of present or future implanted

heart pacemakers differs greatly, so that no general rules can be given.

• Those with metal implants or metal pieces, as well as with hearing aids must consult a

doctor before they enter the areas described above.

Otherwise health hazards may occur.

Hot Parts

CAUTION

Hot surfaces at motor housings, on drive controllers or chokes! Danger of burns!

• Do not touch surfaces of device housings and chokes in the proximity of heat sources!

Danger of burns!

• Do not touch housing surfaces of motors! Danger of burns!

• According to operating conditions, temperatures can be higher than 60 °C (140 °F)

during or after operation.

• Before accessing motors after having switched them off, let them cool down for a

sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated,

the time required for cooling down is five times the thermal time constant specified in the

Technical Data.

• Wear safety gloves or do not work at hot surfaces.

• For certain applications, the manufacturer of the end product, machine or installation,

according to the respective safety regulations, has to take measures to avoid injuries

caused by burns in the end application. These measures can be, for example: warnings,

guards (shielding or barrier), technical documentation.

1.2 Appropriate Use

This product may only be used for the applications mentioned in the

reference documentations (see chapter “Reference Documentations”)

and under the described application, ambient and operating conditions.

Identification

2.1 Type Code

housing dimension; see related dimension sheet also 4) 5) see fig. "Air inlet and outlet of drive controller" 6) observe supply voltage for motor holding brakes 7) find value for control section in project planning manual 8) Suitable for use on a circuit capable of delivering not more than this

SCCR value, 600 V AC or less. The drive series shall be used with

listed AC input line fuses or listed circuit breakers specified in this

documentation.

9) DKC, CZM, BZM: DC bus L+, L-; Mains input L1, L2, L3 10) at PDC_cont 11) class J branch circuit fuse

12) find value for tightening torque in project planning manual, electrical

terminals

13) copper wire; PVC-insulation (conductor temperature 90 °C); Table

13.5.1; Ta ≤ 40 °C

14) plus dissipation of braking resistor

Abb. 3-1: UL ratings and dimensions

A: air intake

B: air outlet

C: mounting surface in control cabinet

dtop: distance top

dbot: distance bottom

Fig. 3-2: Air intake and air outlet at drive controller

Index

2

24V control voltage supply (+24V and 0V) 5-3

A

Appendix 6-1

Appropriate use 1-4

B

Basic connection of holding brake 5-13

Basic connection of motor power 5-13

Basic connection of motor temperature monitoring 5-13

Bb 5-5

DKC 5-5

BR+, BR- 5-11

C

Connection Choke (DR+, DR-) 5-16

Connection cross section

X1 5-3

X12 5-16

X5 5-7

X6 5-10

Connection Diagram 5-2

Connections 5-1

control cabinet

with multiple-line structure 5-20

Control Cabinet 5-20

Control voltage connections 5-3

Cooling Units 5-20

D

DC Bus Capacitors

discharging 6-1

DC bus connection 5-7

Dimensions 3-1

Discharging of DC Bus Capacitors 6-1

Documentations 4-1

DR+, DR- 5-16

dripping or sprayed water 5-20

Drive enable 5-5

Drive halt 5-5

Drive halt (AH) and Drive enable (RF) 5-4

E

Enclosure 5-20

H

Holding brake (BR+, BR-) 5-11

Holding brakes 5-9

I

Identification 2-1

Important notes 1-1

Installation 5-18

Instructions for Use 5-1

Insulation Monitoring 5-4

M

Mains connections

DKC 5-9

moisture condensation 5-21

Motor connection 5-8

Motor holding brake 5-13

Motor power cables 5-8

Motor temperature monitoring 5-9

Motor temperature monitoring (TM+, TM) 5-10

O

Optional Choke Connection for DKC**.3-200-7 5-15

Overcurrent Protection 5-1

P

Programming module 5-14

Protective conductor connections

XE1, XE2 5-16

R

Ratings 3-1

Ready to operate contact

DKC 5-5

Reference Documentations 4-1

S

Safety instructions 1-1

Setting the Drive Address 5-15

Shield Connections 5-17

Switch S2, S3 5-15

T

Technical data Motor holding brake 5-13

Technical description of connector

X1 5-3

X12 5-15

X5 5-6

X6 5-9

XE1, XE2 5-16

Tightening torque

X12 5-15

X5 5-7

XE1 5-17

XE2 5-17

TM+, TM- 5-10

Touch Guard at Devices 5-19

Type code 2-1

DKC 2-1

Type plates 2-1

U

Use

appropriate 1-4

V

Voltage connection for brakes 5-12

W

Courtesy 

Wiring Diagram 5-1

X

X1, Connections for Control voltage 5-3

X12, Optional Choke Connection for DKC**.3-200-7 5-15

X5, DC bus, Motor and Mains Connections 5-6

X6, Motor temperature monitoring 5-9

X7, Connection for Programming module 5-14

XE1, XE2 5-16

XS1, Shield Connection 5-17

XS2, Shield Connection 5-17

XS3, Shield Connection 5-17